Exhaust system component

ABSTRACT

An exhaust system component includes a plurality of branch pipe parts, a collecting pipe part, a first shell member, a second shell member, and a supporting part. The supporting part is formed integrally with one of the first shell member and the second shell member, such that a region surrounded by peripheries of the plurality of branch pipe parts and the collecting pipe part, and a part of a periphery of the supporting part is open to form an opening portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This international application claims the benefit of Japanese Patent Application No. 2012-128945 filed Jun. 6, 2012 in the Japan Patent Office, the entire disclosure of Japanese Patent Application No. 2012-128945 is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to an exhaust system component that constitutes a flow path for exhaust gas from an internal combustion engine.

BACKGROUND ART

Conventionally, an exhaust manifold, various pipes, a catalytic converter, a muffler, etc. have been known as a component (hereinafter, referred to as exhaust system component) that constitutes an exhaust system forming a flow path for an exhaust gas from an internal combustion engine of a vehicle.

Among exhaust manifolds, a known exhaust manifold is provided with: a flange part including a plurality of passage holes, through which exhaust gases respectively from a plurality of exhaust ports of an internal combustion engine with multiple cylinders pass; and a main body, through which the exhaust gases that have flown via each of the passage holes of the flange part from each of the exhaust ports of the internal combustion engine pass (see, Patent Document 1). The main body described in Patent Document 1 includes a plurality of branch pipe parts, each of which is bent in the same direction to be formed in a tubular shape and which are to be respectively connected to the exhaust ports, and includes a collecting pipe part having a shape that is configured to collect the branch pipe parts to form one flow path; the main body as a whole is formed to be a manifold.

Specifically, the main body described in Patent Document 1 is configured with plate-like members forming an outer shell of the main body, and includes recesses (concave portions). In the main body, the branch pipe parts and the collecting pipe part are formed by joining peripheries of the multiple outer shell members, and a space surrounded by the concave portions serves as a flow path for exhaust gas.

Here, respective ends of the branch pipe parts are joined (for example, welded) to peripheries of the passage holes of the flange part so as to secure the exhaust manifold to the internal combustion engine. Generally, the securing to the internal combustion engine is performed by inserting fastening components, such as bolts, into the insertion holes provided in the flange part and fastening the fastening components. For this reason, it is desired that the work through the exhaust manifold can be easily done.

Due to high-temperature exhaust gas from each of the exhaust ports of the internal combustion engine, passing of the exhaust gas through the branch pipe parts and the collecting pipe part causes an increase in a temperature of the outer shell members constituting the main body.

Consequently, thermal stress is generated in the exhaust manifold, particularly, in a section where the plurality of branch pipe parts are merged in the collecting pipe part of the main body (hereinafter, referred to as merging part), requiring inhibition of generation of deformation due to the aforementioned thermal stress in the merging part.

As an exhaust manifold that achieves the aforementioned inhibition of deformation, there is an exhaust manifold that is provided with a plurality of branch pipe parts, one collecting pipe part, and a portion (hereinafter, referred to as skirt portion) formed in a plate-like shape and connecting adjacent ones of the branch pipe parts to each other, and that is formed to be a manifold as a whole (see, Patent Document 2). Moreover, in order to attain workability in securing the exhaust manifold to an internal combustion engine, the skirt portion of the main body described in Patent Document 2 is provided with light-weight holes, which are coaxial with insertion holes.

Here, the main body described in Patent Document 2 is formed in the following manner: one piece of a plate member is pressed to form two portions on the one piece of the plate member, the one portion (hereinafter, referred to as half-split portion) corresponding to a plurality of branch pipe parts, one collecting part, and one outer shell member having at least a skirt portion; and thereafter, the half-split portions are bent so as to face and abut each other.

PRIOR ART DOCUMENTS Patent Documents

Patent Document 1: Japanese Unexamined Patent Application Publication No. 2009-257247

Patent Document 2: Japanese Unexamined Patent Application Publication No. 6-221148

SUMMARY OF THE INVENTION Problems to be Solved by the Invention

In the main body described in Patent Document 2, a joining process, such as welding, is performed after the bending.

The joining process to the main body described in Patent Document 2 involves the following problem: since it is necessary to join peripheries of the light-weight holes in the skirt portion to each other, in addition to join peripheries of members of the branch pipe parts to each other and peripheries of members of the collecting pipe part, requiring many operations in the joining process.

That is to say, in a conventional art, an exhaust system component that includes a plurality of branch pipe parts and one collecting pipe part and that is configured by joining at least two outer shell members to each other to thereby form at least the branch pipe parts and the collecting pipe part involves the following problem: it is not possible to reduce the operations in the joining process while ensuring ease of operation performed via the exhaust system component and inhibiting concentration of stress at a section where the plurality of branch pipe parts are merged.

In view of the above, in one aspect of the present invention, it is desired, in an exhaust system component, to reduce operations for the joining process, and also to ensure ease of operation performed via the exhaust system component and to inhibit concentration of stress at the section where the plurality of branch pipe parts are merged.

Means for Solving the Problems

One aspect of the present invention relates to an exhaust system component that as a whole constitutes a flow path for guiding exhaust gas from an internal combustion engine having a plurality of cylinders.

The exhaust system component in one aspect of the present invention comprises a plurality of branch pipe parts, a collecting pipe part, a first shell member, a second shell member, and a supporting part.

The plurality of branch pipe parts constitute respectively a plurality of flow paths for guiding the exhaust gas from the internal combustion engine. The collecting pipe part collects the plurality of branch pipe parts to guide exhaust gas from the plurality of branch pipe parts, to the air or to a different exhaust system component that is different from the exhaust system component and that is located at a downstream side.

The first shell member integrally constitutes a part of an outer shell forming, in each of the plurality of branch pipe parts, a flow path from the internal combustion engine to the collecting pipe part, and a part of an outer shell forming, in the collecting pipe part, a flow path from each of the plurality of branch pipe parts to a downstream side.

The second shell member constitutes a part of the outer shell forming, in each of the plurality of branch pipe parts, the flow path from the internal combustion engine to the collecting pipe part, and a part of the outer shell forming, in the collecting pipe part, the flow path from each of the plurality of branch pipe parts to the downstream side; the second shell member is formed separately from the first shell member. Moreover, the second shell member has a concave portion that forms flow paths in the plurality of branch pipe parts and a flow path in the collecting pipe part when the second shell member is joined to the first shell member.

That is, in the exhaust system component, the branch pipe parts forming respectively the plurality of flow paths, and the collecting pipe part forming the flow path into which these branch pipe parts are collected are configured by joining the second shell member to the first shell member.

The supporting part in the exhaust system component connects two branch pipe parts adjacent to each other among the plurality of branch pipe parts. The supporting part is integrally formed with one of the first shell member and the second shell member, such that a region surrounded by peripheries of the branch pipe parts and the collecting pipe part and by a part of a periphery of the supporting part is open to form an opening portion.

That is, in the exhaust system component, the region surrounded by peripheries of two branch pipe parts adjacent to each other and the collecting pipe part and by the part of the periphery of the supporting part is open to form the opening portion. Into the opening of the opening portion, a tool for fastening a fastening component can be easily inserted. “Fastening component” used herein refers to a component for securing the exhaust system component to a separate device (internal combustion engine) and the like, and is, for example, bolts and screws, etc. In addition, through the opening of the opening portion, a component that is different from the exhaust system component, and a fastening component, which are to be attached to the separate device, can be manipulated.

As a result of these configurations, the exhaust system component as above can improve operability.

In addition, according to the aforementioned exhaust system component, the supporting part that connects the adjacent branch pipe parts is provided, thereby enhancing stiffness of a section where the plurality of the branch pipe parts are merged in the exhaust system component. Consequently, according to the exhaust system component configured as above, it is possible to inhibit thermal stress that is generated in the shell members due to temperature changes of the shell members caused by exhaust gases passing therethrough; and it is possible to inhibit breakage in the section where the plurality of branch pipe parts are merged.

Moreover, according to the aforementioned exhaust system component, the exhaust system component can be structured by joining a section where the periphery of the first shell member and the periphery of the second shell member abut each other. That is to say, unlike a conventional exhaust system component, according to the exhaust system component, welding of the periphery of the supporting part is not necessary to form the opening of the opening portion, resulting in reduction of a joining (welding) process for forming the exhaust system component.

In other words, according to the above-described exhaust system component, in the exhaust system component comprising the plurality of branch pipe parts and one piece of the collecting pipe part, the branch pipe parts and the collecting pipe part being configured by joining at least two shell members, concentration of stress at the section where the plurality of branch pipe parts are merged can be inhibited, and work for the joining process can be reduced while ensuring ease of operation performed via the exhaust system component.

The exhaust system component configured as above can be applied to an exhaust system component provided with two or more shell members.

The exhaust system component may comprise at least one of: a plurality of the first shell members; and a plurality of the second shell members.

That is, the exhaust system component may be configured by: a combination of one piece of the first shell member and a plurality of the second shell members; a combination of a plurality of the first shell members and one piece of the second shell member; a combination of a plurality of the first shell members and a plurality of the second shell members; or the like.

In the exhaust system component comprising at least one of: a plurality of the first shell members; and a plurality of the second shell members, if each of the branch pipe parts is configured with two shell members, shell members that do not constitute the branch pipe parts do not need to have a section constituting the branch pipe parts. According to the exhaust system component comprising at least one of: a plurality of the first shell members; and a plurality of the second shell members, variations of the shell members constituting the branch pipe parts are possible, and improved flexibility in designing the exhaust system component can be obtained.

Moreover, each of the plurality of branch pipe parts may be bent in the same direction and formed in a tubular shape.

In this case, the exhaust system component may include a flange part in a plate-like shape to be connected to the internal combustion engine. The flange part may have: connection holes that respectively connects the plurality of branch pipe parts respectively to exhaust ports of the internal combustion engine; and at least one insertion hole, into which a fastening component is inserted to a position away from the connection holes along a direction of the bending of each of the plurality of branch pipe parts.

In the exhaust system component, the supporting part may be formed such that the opening of the opening portion is formed along the direction of the bending of the branch pipe parts connected to the flange part; the supporting part is formed at a position where the opening of the opening portion encloses a region around an axis as a center, the axis orthogonal to an outer surface of the flange part and extending from a center of the insertion hole.

That is, in the exhaust system component, the supporting part may be formed such that, the position of the opening of the opening portion relative to the insertion hole of the flange part can secure a path (tool trajectory) along which a fastening tool for fastening the fastening component can pass.

According to the above-described exhaust system component, when the exhaust system component is secured to the internal combustion engine, the fastening tool can be easily inserted into the opening of the opening portion. Consequently, the exhaust system component enables an ensured operability in securing the exhaust system component to the internal combustion engine.

Moreover, the exhaust system component includes an exhaust manifold, and a merging member that merges a plurality of exhaust pipes into one exhaust pipe.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is one example of a view showing a configuration of a part of an exhaust system provided with an exhaust manifold as an exhaust system component to which the present invention is applied.

FIG. 2A is a top view of the exhaust manifold, and FIG. 2B is a front view of the exhaust manifold.

FIG. 3A is a side view of the exhaust manifold; FIG. 3B is a cross sectional view taken along a line IIIB-IIIB in FIG. 2A; and FIG. 3C is a cross sectional view taken along a line IIIC-IIIC in FIG. 2B.

FIG. 4 is one example of a view showing a lower shell member that constitutes the exhaust system component.

FIG. 5 is one example of a view showing an intermediate shell member that constitutes the exhaust system component.

FIG. 6 is one example of a view showing an upper shell member that constitutes the exhaust system component.

FIG. 7A is a top view of an exhaust manifold, and FIG. 7B is a front view of the exhaust manifold.

FIG. 8A is a side view of the exhaust manifold; FIG. 8B is a cross sectional view taken along a line VIIIB-VIIIB in FIG. 7A; and FIG. 8C is a cross sectional view taken along a line VIIIC-VIIIC in FIG. 7B.

FIG. 9 is a view showing a schematic configuration of an exhaust system having a merging member.

FIG. 10A is an enlarged view of the merging member in FIG. 9; FIG. 10B is a cross sectional view taken along a line XB-XB in FIG. 10A; and FIG. 10C is a cross sectional view taken along a line XC-XC in FIG. 10A.

EXPLANATION OF REFERENCE NUMERALS

1,160 . . . exhaust system, 10,70 . . . exhaust manifold, 12,72 . . . flange part, 16,74 . . . connection hole, 18,76 . . . insertion hole, 20,78 . . . main body, 22,81 . . . branch pipe part, 24 . . . collecting pipe part, 28,88,89 . . . supporting part, 35,40,45,83,90 . . . shell member, 39,49,85,87,93,95 . . . concave portion, 51,101,102 . . . opening portion, 60 . . . catalytic converter, 65 . . . exhaust pipe, 120 . . . internal combustion engine

MODE FOR CARRYING OUT THE INVENTION

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

First Embodiment

<Configuration of Exhaust System>

As shown in FIG. 1, an exhaust system 1 is a system that guides exhaust gas from an internal combustion engine 120 having a plurality of cylinders, into the air.

The internal combustion engine 120 is an in-line 4-cylinder internal combustion engine having four cylinders of first to fourth cylinders #1 to #4 arranged in a straight line, or a V-type internal combustion engine having four cylinders of first to fourth cylinders #1 to #4 arranged in a V shape.

The exhaust system 1 is at least provided with an exhaust manifold 10, a catalytic converter 60, an exhaust pipe 65. The exhaust system 1 includes one or more known mufflers and end pipes, which are not shown.

Among these components, the catalytic converter 60 is a mechanism that contains a known catalyst, which purifies exhaust gas from the exhaust manifold 10; the catalytic converter 60 guides the exhaust gas purified by the catalyst to the exhaust pipe 65.

The exhaust pipe 65 is a known pipe constituting a flow path for the exhaust gas, and constitutes a flow path to guide the exhaust gas purified by the catalytic converter 60 into the air.

<Overall Configuration of Exhaust Manifold>

As shown in FIG. 2A, FIG. 2B, FIG. 3A, FIG. 3B, and FIG. 3C, the exhaust manifold 10 includes a flange part 12 and an exhaust manifold main body (hereinafter, referred to as main body) 20.

Among these components, the flange part 12 is a plate-like member, which is to be connected to the internal combustion engine 120. The flange part 12 is provided with connection holes 16-n, which are to be connected respectively to exhaust ports P1 to P4 of the internal combustion engine 120; the flange part 12 is also provided with a plurality of holes (hereinafter, referred to as insertion holes) 18-m, through which fastening components are inserted. “Fastening component” used herein refers to known parts for securing the flange part 12 to the internal combustion engine 120, and are, for example, bolts and screws. In the present embodiment, the suffix letter “n” indicates a number of cylinders arranged in straight in the internal combustion engine 120 (in the embodiment, n=4), and the suffix letter “m” indicates a number of the insertion holes 18 (in the embodiment, m=5).

Next, the main body 20 includes an upper shell member 35, an intermediate shell member 40, and a lower shell member 45. In the main body 20, these members 35, 40, and 45 are joined to constitute a flow path that guides exhaust gas from the internal combustion engine 120 to the catalytic converter 60.

The main body 20 includes branch pipe parts 22-n and a collecting pipe part 24.

The branch pipe parts 22 form respective flow paths for guiding exhaust gases respectively from the exhaust ports P1 to P4 of the internal combustion engine 120. Each of the branch pipe parts 22 is formed in a bent tubular shape; one ends of the branch pipe parts 22 are connected respectively to peripheries of the connection holes 16 of the flange part 12. The connection of the branch pipe parts 22 to the flange part 12 is made such that bending directions of the branch pipe parts 22, which project from the flange part 12, are in the same direction.

The collecting pipe part 24 collects ends of the branch pipe parts 22, which are not connected to the flange part 12, to form a flow path for guiding exhaust gases from the branch pipe parts 22 to at least one exhaust pipe 65. In the present embodiment, the collecting pipe part 24 is connected to the exhaust pipe 65 via the catalytic converter 60.

Here, in the present embodiment, the insertion holes 18 of the flange part 12 are provided at a total of five positions: two positions along an upper side of the flange part 12 (upper side in FIG. 2B); and three positions along a lower side of the flange part 12 (lower side in FIG. 2B). One of the five insertion holes 18, i.e., the insertion hole 18-3, is provided at a position where an axis passing through a center of the insertion hole 18-3 and orthogonal to an outer surface of the flange part 12 is interposed between the branch pipe part 22-2 and the branch pipe part 22-3.

The main body 20 is provided with a supporting part 28. The supporting part 28 is a member that connects adjacent two of the branch pipe parts 22 to each other. The supporting part 28 in the present embodiment is provided as a member that connects the branch pipe part 22-2 and the branch pipe part 22-3 to each other.

In addition, the supporting part 28 in the present embodiment is provided such that a region surrounded by peripheries of the branch pipe parts 22 and the collecting pipe part 24, and a part of a periphery of the supporting part 28 is open to form an opening portion 51. The supporting part 28 in the present embodiment is provided such that the opening of the opening portion 51 encloses a specified region (hereinafter, referred to as tool trajectory) around the axis, as a center, which is orthogonal to the outer surface of the flange part 12 and which extends from the center of the insertion hole 18-3. Here, the specified region is a region through which a tool for fastening the fastening components, for example, bolts and screws, can pass.

For example, the opening of the opening portion 51 in the present embodiment is arranged coaxially with the insertion hole 18-3; the specified region is a region located coaxially with the opening of the opening portion 51 and with the insertion hole 18-3. “Coaxially” used herein includes a state of being coaxial as well as a state where respective centers are deviated from each other within a predefined error range.

<Detailed Configuration of Main Body>

Next, explanations are given with respect to detailed configurations of the main body 20.

The main body 20, i.e., each of the upper shell member 35, the intermediate shell member 40, and the lower shell member 45, all of which forming the branch pipe parts 22 and the collecting pipe part 24, is a plate-like member having a recess (concave portion).

The concave portions formed in the upper shell member 35, the intermediate shell member 40, and the lower shell member 45 are formed by, for example, press-molding the plate-like members.

As shown in FIG. 4, the lower shell member 45 is provided with lower branch parts 46-1 to 46-4, a lower collecting part 48, and a supporting section 53; the lower branch parts 46-1 to 46-4, the lower collecting part 48, and the supporting section 53 are integrally formed.

The lower branch parts 46-1 to 46-4 are portions that respectively constitute a part of respective outer shells forming the branch pipe parts 22-1 to 22-4. The lower branch parts 46-1 to 46-4 respectively have concave portions 47-1 to 47-4, each of which is a semicircular recess.

The lower collecting part 48 is a portion that constitutes a part of an outer shell of the collecting pipe part 24. The lower collecting part 48 has a concave portion 49, which is a semicircular recess.

In the present embodiment, the concave portion 47-1, the concave portion 47-4, and the concave portion 49 in the lower shell member 45 are formed to be a contiguous recess extending from each of the concave portion 47-1 and the concave portion 47-4 to the concave portion 49.

The supporting section 53 is a portion that connects the lower branch part 46-2 and the lower branch part 46-3 and that serves as the supporting part 28. The supporting section 53 is provided such that a region surrounded by a periphery of the lower branch part 46-2, a periphery of the lower collecting part 48, a periphery of the lower branch part 46-3, and a periphery of the supporting section 53 is open to form the opening portion 51.

Here, the supporting section 53 in the present embodiment is provided such that the opening of the opening portion 51 is located coaxially with the insertion hole 18-3 of the flange part 12 along the tool trajectory.

A manufacturing method of the supporting section 53 of the lower shell member 45 will be explained. Specifically, in manufacturing the lower shell member 45, when a plate-like member is pressed to form the lower branch parts 46-1 to 46-4 and the lower collecting part 48, a skirt portion is left, which is a portion having a plate-like shape between the lower branch part 46-2 and the lower branch part 46-3. The opening of the opening portion 51 is formed in the skirt portion by drilling such that a part of the skirt portion is left as the supporting section 53.

As shown in FIG. 5, the intermediate shell member 40 includes intermediate branch parts 41-1 and 41-4, and an intermediate collecting part 44; these intermediate branch parts 41-1 and 41-4, and the intermediate collecting part 44 are formed integrally.

The intermediate branch parts 41-1 and 41-4 are portions that respectively constitute a part of respective outer shells forming the branch pipe parts 22-1 and 22-4. The intermediate branch parts 41-1 and 41-4 respectively have concave portions 42-1 and 42-4, each of which is a semicircular recess.

The intermediate collecting part 44 is a plate-like portion that constitutes a part of a portion where the branch pipe part 22-1 and the branch pipe part 22-2 are collected in the collecting pipe part 24.

That is, in the main body 20 of the present embodiment, a periphery of the intermediate shell member 40 is joined to peripheries of the lower branch parts 46-1, 46-4 and the lower collecting part 48 in the lower shell member 45, thereby to form a tubular region surrounded by the intermediate branch part 41-1 and the lower branch part 46-1, i.e., the branch pipe part 22-1 is formed by the concave portion 42-1 and the concave portion 47-1. Also, a tubular region surrounded by the intermediate branch part 41-4 and the lower branch part 46-4 is formed, i.e., the branch pipe part 22-4 is formed by the concave portion 42-4 and the concave portion 47-4.

In addition, a region surrounded by the intermediate collecting part 44 and the lower collecting part 48 is formed, i.e., a region where the branch pipe part 22-1 and the branch pipe part 22-4 of the collecting pipe part 24 are collected is formed by a flat surface constituting the intermediate collecting part 44 and the concave portion 49.

As shown in FIG. 6, the upper shell member 35 includes upper branch parts 36-2 and 36-3 and an upper collecting part 38.

Among these components, the upper branch part 36-2 and the upper branch part 36-3 are portions that respectively constitute part of respective outer shells forming the branch pipe part 22-2 and the branch pipe part 22-3. The upper branch part 36-2 and the upper branch part 36-3 respectively have a concave portion 37-2 and a concave portion 37-3, each of which is a semicircular recess.

The upper collecting part 38 is a portion that constitutes a part of an outer shell forming the collecting pipe part 24. The upper collecting part 38 has a concave portion 39, which is a semicircular recess.

Here, these concave portion 37-2, the concave portion 37-3, and the concave portion 39 are formed to be a contiguous recess extending from each of the concave portion 37-2 and the concave portion 37-3 to the concave portion 39.

Here, the upper shell member 35 has an open space between the upper branch parts 36-2 and 36-3.

That is, in the main body 20 of the present embodiment, peripheries of the upper branch part 36-2 and the upper branch part 36-3 in the upper shell member 35 are respectively joined to the lower branch parts 46-2 and 46-3 in the lower shell member 45, to form a tubular region surrounded by the upper branch part 36-2 and the lower branch part 46-2, i.e., the branch pipe part 22-2 is formed by the concave portion 37-2 and the concave portion 47-2. Also, a tubular region surrounded by the upper branch part 36-3 and the lower branch part 46-3 is formed, i.e., the branch pipe part 22-3 is formed by the concave portion 37-3 and the concave portion 47-3.

Moreover, in the main body 20 in the present embodiment, a periphery of the upper collecting part 38 in the upper shell member 35 is joined to a periphery of the intermediate collecting part 44 in the intermediate shell member 40, to form a portion surrounded by the intermediate collecting part 44 and the upper collecting part 38, i.e., a region where the branch pipe part 22-2 and the branch pipe part 22-3 of the collecting pipe part 24 are collected is formed by a flat surface constituting the intermediate collecting part 44 and the concave portion 39. Moreover, in the present embodiment, peripheries of the upper branch part 36-2 and the upper branch part 36-3 in the upper shell member 35 are respectively joined to the lower branch parts 46-1 and 46-4 in the lower shell member 45, thereby enabling the supporting section 53 in the lower shell member 45 to function as the supporting part 28.

Here, “join” used in the embodiment refers to a known method for achieving connection and fixation between members and includes, for example, welding.

Effect of First Embodiment

As described above, in the exhaust manifold 10 of the present embodiment, the region surrounded by the peripheries of the branch pipe part 22-2 and the branch pipe part 22-3, the periphery of the collecting pipe part 24, and the part of the periphery of the supporting section 53 (supporting part 28) is open to form the opening portion 51. Moreover, the supporting section 53 (supporting part 28) is provided such that the opening of the opening portion 51 is located on an extension of the tool trajectory, relative to the insertion hole 18-3 provided in the flange part 12.

Thus, according to the exhaust manifold 10, when the exhaust manifold 10 is fixed to the internal combustion engine 120, a fastening tool, which fastens fastening components, such as bolts, can be easily inserted via the opening of the opening portion 51, and an improved operability in the fastening of the fastening components can be achieved.

In addition, according to the exhaust manifold 10, since the supporting part 28 that connects the branch pipe parts 22-2 and 22-3, which are adjacent to each other, is provided, stiffness of the portion where the plurality of the branch pipe parts 22 are merged in the exhaust manifold 10 can be enhanced. Consequently, according to the exhaust manifold 10, it is possible to inhibit thermal stress that is generated in the lower shell member 45 and the upper shell member 35 due to temperature changes of the lower shell member 45 and the upper shell member 35 caused by exhaust gases passing therethrough; it is possible to inhibit breakage in the region where the branch pipe parts 22 are merged.

Moreover, according to the exhaust manifold 10, the supporting part 28 can be formed by joining the periphery of the upper shell member 35 to the lower branch parts 46-2 and 46-3 in the lower shell member 45. That is to say, unlike a conventional exhaust manifold, according to the exhaust manifold 10, forming of the opening of the opening portion 51 does not require welding of peripheries of openings to each other. Thus, according to the exhaust manifold 10, joining (welding) process for structuring the supporting part 28 of the exhaust manifold 10 can be reduced.

In other words, according to the exhaust manifold 10 that is provided with a plurality of the branch pipe parts 22-n and one piece of the collecting pipe part 24, the branch pipe parts 22 and the collecting pipe part 24 being configured by joining the shell members 35, 40, and 45, ease of operation performed via the exhaust manifold 10 can be ensured; concentration of stress at the region where the plurality of branch pipe parts 22 are merged can be inhibited; and work for the joining process can be reduced.

Second Embodiment

Next, the second embodiment of the present invention will be explained.

The second embodiment of the present invention is mainly different from the first embodiment with respect to configurations of an exhaust manifold to which the present invention is applied. Accordingly, in the present embodiment, the same configurations as those in the first embodiment are given with the same reference numerals, and will not be explained here. Different configurations of the exhaust manifold from the first embodiment will be mainly explained.

<Overall Configuration of Exhaust Manifold>

As shown in FIG. 7A, FIG. 7B, FIG. 8A, FIG. 8B, and FIG. 8C, an exhaust manifold 70 includes a flange part 72 and a main body 78.

The flange part 72 is a plate-like member, which is to be connected to the internal combustion engine 120. The flange part 72 is provided with connection holes 74-n and insertion holes 76-m. The connection holes 74-n in the present embodiment are connected respectively to the exhaust ports P1 to P4 of the internal combustion engine 120 in the same manner as in the connection holes 16-n in the first embodiment.

Next, the main body 78 includes an upper shell member 83 and a lower shell member 90; the shell members 83 and 90 are joined to constitute a flow path inside the manifold, which guides exhaust gas from the internal combustion engine 120 to the catalytic converter 60.

The main body 78 includes branch pipe parts 81 n and a collecting pipe part 82.

Among these components, the branch pipe parts 81 form respective flow paths for respective exhaust gases guided from the internal combustion engine 120. Each of the branch pipe parts 81 is formed in a bent tubular shape, and one ends of the branch pipe parts 81 are connected respectively to peripheries of the connection holes 74 of the flange part 72. The connection of the branch pipe parts 81 to the flange part 72 is made such that bending directions of the branch pipe parts 81, which project from the flange part 72, are in the same direction.

The collecting pipe part 82 collects ends of the branch pipe parts 81-n, which are not connected to the flange part 72, to form a flow path for guiding exhaust gases from the branch pipe parts 81 to at least one exhaust pipe 65.

Here, in the present embodiment, the insertion holes 76 of the flange part 72 are provided at a total of five positions: three positions along an upper side of the flange part 72 (upper side in FIG. 7B); and two positions along a lower side of the flange part 72 (lower side in FIG. 7B). Among the five insertion holes 76, the insertion hole 76-2 and the insertion hole 76-4 are provided in the following positions: the insertion hole 76-2 is at the position where an axis that passes through a center of the insertion hole 76-2 and that are orthogonal to an outer surface of the flange part 72 is interposed between the branch pipe part 81-1 and the branch pipe part 81-2; and the insertion hole 76-4 is at the position where an axis that passes through a center of the insertion hole 76-4 and that are orthogonal to the outer surface of the flange part 72 is interposed between the branch pipe part 81-3 and the branch pipe part 81-4 (see FIG. 8C).

The main body 78 is provided with two supporting parts 88 and 89.

The supporting part 88 connects between the branch pipe part 81-1 and the branch pipe part 81-2. The supporting part 88 is provided such that a region surrounded by a periphery of the branch pipe part 81-1, a periphery of the collecting pipe part 82, a periphery of the branch pipe part 81-2, and a part of a periphery of the supporting part 88 is open to form an opening portion 101.

The supporting part 89 connects between the branch pipe part 81-3 and the branch pipe part 81-4. The supporting part 89 is provided such that a region surrounded by a periphery of the branch pipe part 81-3, a periphery of the collecting pipe part 82, a periphery of the branch pipe part 81-4, and a part of a periphery of the supporting part 89 is open to form an opening portion 102.

Moreover, the supporting part 88 is provided such that the opening of the opening portion 101 encloses a tool trajectory around the axis, as a center, which is orthogonal to the outer surface of the flange part 72 and which extends from the center of the insertion hole 76-1; the supporting part 89 is provided such that the opening of the opening portion 102 encloses a tool trajectory around the axis, as a center, which is orthogonal to the outer surface of the flange part 72 and which extends from the center of the insertion hole 76-4. More specifically, in the present embodiment, the supporting part 88 may be provided such that the insertion hole 76-1 is located coaxially with the opening of the opening portion 101; the supporting part 89 may be provided such that the insertion hole 76-4 is located coaxially with the opening of the opening portion 102.

<Detailed Configuration of Main Body>

Next, explanations are given with respect to detailed configurations of the main body 78.

Each of the upper shell member 83 and the lower shell member 90, both of which constitute the main body 78, is plate-like member having a recess (concave portion). The concave portions formed in the upper shell member 83 and the lower shell member 90 are formed by, for example, press-molding the plate-like members.

The lower shell member 90 is provided with lower branch parts 91-1 to 91-4, a lower collecting part 94, and supporting sections 96 and 97; the lower branch parts 91-1 to 91-4, the lower collecting part 94, and the supporting sections 96 and 97 are integrally formed.

The lower branch parts 91-1 to 91-4 are portions that respectively constitute a part of respective outer shells forming the branch pipe parts 81 -1 to 81-4. The lower branch parts 91-1 to 91-4 respectively have concave portions 93-1 to 93-4, each of which is a semicircular recess.

The lower collecting part 94 is a portion that constitutes a part of an outer shell of the collecting pipe part 82. The lower collecting part 94 has a concave portion 95, which is a semicircular recess.

In the present embodiment, the concave portions 93-1 to 93-4 and the concave portion 95 are formed to be a contiguous recess extending from each of the concave portions 93-1 to 93-4 to the concave portion 95.

The supporting section 96 is a portion that connects the lower branch part 91-1 and the lower branch part 91-2. In the supporting section 96, a region surrounded by a periphery of the lower branch part 91-1, a periphery of the lower collecting part 94, a periphery of the lower branch part 91-2, and the supporting section 96 is open to form the opening portion 101.

The supporting section 97 is a portion that connects the lower branch part 91-3 and the lower branch part 91-4. In the supporting section 97, a region surrounded by a periphery of the lower branch part 91-3, a periphery of the lower collecting part 94, a periphery of the lower branch part 91-4, and the supporting section 97 is open to form the opening portion 102.

Here, in the present embodiment, the supporting section 96 is provided such that the opening of the opening portion 101 is located coaxially with the insertion hole 78-2 of the flange part 72 along the tool trajectory; the supporting section 97 is provided such that the opening of the opening portion 102 is located coaxially with the insertion hole 78-4 of the flange part 72 along the tool trajectory.

The upper shell member 83 includes upper branch parts 84-1 to 84-4 and an upper collecting part 86.

Among these components, the upper branch parts 84-1 to 84-4 are portions that respectively constitute a part of respective outer shells forming the branch pipe parts 81-1 to the branch pipe part 81-3 in the upper shell member 83. The upper branch parts 84-1 to 84-4 respectively have concave portions 85-1 to 85-4, each of which is a semicircular recess.

The upper collecting part 86 is a portion that constitutes a part of an outer shell forming the collecting pipe part 82. The upper collecting part 86 has a concave portion 87, which is a semicircular recess.

Here, in the present embodiment, the concave portions 85-1 to 85-4, and the concave portion 87 are formed to be a contiguous recess extending from each of the concave portions 85-1 to 85-4 to the concave portion 87.

Here, the upper shell member 83 has an open space among each of the upper branch parts 84.

That is, in the main body 78 of the present embodiment, a periphery of the upper shell member 83 is joined to a periphery of the lower shell member 90, to form a tubular region surrounded by the upper branch parts 84-n and the lower branch parts 91-n, i.e., the branch pipe parts 81-n are formed by the concave portions 85-n and the concave portions 93-n. Also, a tubular region surrounded by the upper collecting part 86 and the lower collecting part 94 is formed, i.e., the collecting pipe part 82 is formed by the concave portion 87 and the concave portion 95.

Moreover, the main body 78 in the present embodiment, peripheries of the upper branch parts 84-1 and 84-2 in the upper shell member 83 are respectively joined to the lower branch parts 91-1 and 91-2 in the lower shell member 90, thereby enabling the supporting section 96 in the lower shell member 90 to function as the supporting part 88. Peripheries of the upper branch parts 84-3 and 84-4 in the upper shell member 83 are respectively joined to the lower branch parts 91-3 and 91-4 in the lower shell member 90, thereby enabling the supporting section 97 in the lower shell member 90 to function as the supporting part 89.

Effect of Second Embodiment

As described above, the same effects as those obtained by the exhaust manifold 10 of the first embodiment can be obtained by the exhaust manifold 70 of the present embodiment.

Other Embodiments

Although the embodiments of the present invention have been described above, the present invention should not be limited to the aforementioned embodiments, and can be carried out in various manners without departing from the main idea of the present invention.

For example, in the above-described embodiments, a number of the branch pipe parts 22 in the main body 20 and a number of the branch pipe parts 81 in the main body 78 are four; however, the numbers of the branch pipe parts 22 and 81 are not limited to the numbers in the above-described embodiments. That is, any number of the branch pipe parts 22 and 81 may be used as long as such a number is specified depending on a number of cylinders of the internal combustion engine 120.

Moreover, in the above-described embodiments, the numbers of the shell members 35, 40, 45, 83, 90 constituting the main bodies 20 and 78 are two or three; however, the number of the shell members constituting the main body is not limited to two or three, and may be any numbers. That is, the main body may be constituted by a combination of two shell members, or a combination of three or more shell members.

Although in the above-described embodiments, the shape of the branch pipe parts 22 and 81 has a bent shape, shapes of the branch pipe parts 22 and 81 are not limited to the bent shape and may be, for example, a straight pipe.

In the above-described embodiments, an object to which the present invention is applied is an exhaust manifold; however, an object to which the present invention is applied is not limited to an exhaust manifold.

That is, an object to which the present invention is applied may be any exhaust system component that is provided with a plurality of branch pipe parts and one collecting pipe part, the branch pipe parts and the collecting pipe part being configured by joining at least two shell members.

As an object to which the present invention is applied may be, specifically, as shown in FIG. 9, FIG. 10A, FIG. 10B, and FIG. 10C, a merging member 150 in an exhaust system 160 that is provided with: exhaust pipes 130 and 131 through which exhaust gas from the internal combustion engine 120 passes; a merging member 150 that merges the exhaust pipes 130 and 131; and exhaust pipes 133 and 134 that guide exhaust gas that has passed through the merging member 150.

More specifically, as shown FIG. 10A, the merging member 150 includes: pipe connection parts 151 and 152, to which the exhaust pipes 130 and 131 are connected; pipe connection parts 153 and 154, to which the exhaust pipes 133 and 134 are connected; a merge-splitting part 155 that merges exhaust gases from the pipe connection parts 151 and 152 and guides the exhaust gases to the pipe connection parts 153 and 154; and a supporting part 156 that connects between the pipe connection part 151 and the pipe connection part 152.

Here, as shown in FIG. 10B and FIG. 10C, the merging member 150 includes two shell members 158 and 159, each of which is a plate-like member having a recess (concave portion); the merging member 150 is formed by joining the shell members 158 and 159.

That is, the pipe connection parts 151 and 152, the pipe connection parts 153 and 154, and the merge-splitting part 155 are formed by joining the shell members 158 and 159, i.e., these components are portions configured with the shell members 158 and 159.

Here, the supporting part 156 is provided in one of the shell member 158 and the shell member 159. In the example illustrated in FIG. 10B and FIG. 10C, the supporting part 156 is provided in the shell member 159.

Moreover, the supporting part 156 is provided such that a region surrounded by peripheries of the pipe connection parts 151 and 152 of one member of the shell member 158 and the shell member 159, the one member provided with the supporting part 156, a periphery of the merge-splitting part 155, and a periphery of the supporting part 156 is open to form an opening portion 157.

According to the merging member 150, separate parts that are not the merging member 150 or fastening components, which are to be attached to another device, can be operated through the opening of the opening portion 157. As a result, according to the merging member 150, improved operability in operation with the separate parts or the fastening components can be obtained.

Corresponding Relationship Between Embodiments and Claims

Lastly, the relationship between descriptions in the above-described embodiments and descriptions in clams will be explained.

The upper shell members 35 and 83, the lower shell members 45 and 90, and the intermediate shell member 40 in the above-described embodiments correspond to one example of a first shell member and a second shell member in the descriptions of the claims; the flange parts 12 and 72 correspond to one example of a flange part in the descriptions of the claims.

Furthermore, the supporting parts 28, 88, and 89 in the above-described embodiments correspond to one example of a supporting part in the descriptions of the claims. 

1. An exhaust system component that as a whole constitutes a flow path for guiding exhaust gas from an internal combustion engine having a plurality of cylinders, the exhaust system component comprising: a plurality of branch pipe parts that constitute respectively a plurality of flow paths for guiding the exhaust gas from the internal combustion engine; a collecting pipe part that collects the plurality of branch pipe parts to guide exhaust gas from the plurality of branch pipe parts, to the air or to a different exhaust system component that is different from the exhaust system component and that is located at a downstream side; a first shell member that integrally constitutes a part of an outer shell forming, in each of the plurality of branch pipe parts, a flow path from the internal combustion engine to the collecting pipe part, and a part of an outer shell forming, in the collecting pipe part, a flow path from each of the plurality of branch pipe parts to the air or to the different exhaust system component that is different from the exhaust system component and that is located at the downstream side; a second shell member that constitutes a part of the outer shell forming, in each of the plurality of branch pipe parts, the flow path from the internal combustion engine to the collecting pipe part, and a part of the outer shell forming, in the collecting pipe part, the flow path from each of the plurality of branch pipe parts to the air or to the different exhaust system component that is different from the exhaust system component and that is located at the downstream side, the second shell member being formed separately from the first shell member, and the second shell member having a concave portion that forms flow paths in the plurality of branch pipe parts and a flow path in the collecting pipe part when the second shell member is joined to the first shell member; and a supporting part that connects two branch pipe parts adjacent to each other among the plurality of branch pipe parts, wherein the supporting part is integrally formed with one of the first shell member and the second shell member, such that a region surrounded by peripheries of the two branch pipe parts and the collecting pipe part and by a part of a periphery of the supporting part is open to form an opening portion.
 2. The exhaust system component according to claim 1, further comprising at least one of: a plurality of the first shell members; and a plurality of the second shell members.
 3. The exhaust system component according to claim
 1. wherein each of the plurality of branch pipe parts is bent in a same direction and formed in a tubular shape, wherein the exhaust system component includes a flange part in a plate-like shape to be connected to the internal combustion engine, the flange part having: a plurality of connection holes that respectively connects the plurality of branch pipe parts respectively to a plurality of exhaust ports of the internal combustion engine; and at least one insertion hole, into which a fastening component is inserted to a position away from the connection holes along a direction of the bending of each of the plurality of branch pipe parts, wherein the supporting part is formed such that the opening of the opening portion is formed along the direction of the bending of the plurality of branch pipe parts connected to the flange part, and the supporting part is formed at a position where the opening of the opening portion encloses a region around an axis as a center, the axis orthogonal to an outer surface of the flange part and extending from a center of the insertion hole.
 4. The exhaust system component according to claim 1, wherein the exhaust system component is an exhaust manifold.
 5. The exhaust system component according to claim 1, wherein the exhaust system component is a merging member that merges a plurality of exhaust pipes into one exhaust pipe.
 6. The exhaust system component according to claim 1, wherein the opening portion is formed such that the opening of the opening portion includes a region enabling a tool for fastening a fastening component to pass therethrough.
 7. The exhaust system component according to claim 1, wherein the supporting part is a section formed in a plate-like shape. 